Method of optimising the output of a sensor for indicating the relative location of a mettalic object

ABSTRACT

Method of optimizing output of sensor for indicating location of metallic object. Sensor having primary electromagnetic coil to generate time varying magnetic field; secondary electromagnetic coil to detect time varying magnetic field as affected, by object to output, on basis of detected time varying magnetic field, signal indicative of location of object. Method includes steps of: supplying primary coil with alternating-current to result generated time varying magnetic field; locating object in first-position and recording signal output by secondary electromagnetic coil for range of frequencies of supplied alternating-current; locating object in second-position and recording signal output by secondary electromagnetic coil for range of frequencies of supplied alternating-current; calculating, for each of frequencies, a value for span to offset ratio of measured signals on basis of respective signals measured for object in first and second positions; determining frequency of supplied alternating-current which provides maximum span to offset ratio on basis of calculations.

FIELD

The present invention relates to a method of optimising the output of asensor used for sensing a metallic object through another metallicobject. In particular, but not exclusively, the present inventionrelates to a method of optimising the output of a sensor used formeasuring the relative position of a control rod within a nuclearreactor from within a metallic probe tube housing the sensor.

BACKGROUND

Means for measuring or detecting the position of a control rod within anuclear reactor are limited by the fact that the measurement needs to bemade within the primary water for the nuclear reactor.

A conventional method for determining the relative location of a controlin a nuclear reactor is to use a metallic probe tube which extends intothe primary water region, and which houses a coil of wire forming aninductive element that forms part of an electrical circuit.

The probe tube is positioned such that a metallic leadscrew attached tothe control rod moves telescopically over the probe tube as the controlrod is moved in and out of the nuclear reactor to regulate the fissionreaction therein.

As the leadscrew moves over the probe tube the voltage across theinductor changes because of magnetic coupling effects. This change involtage is directly proportional to the position of the leadscrew andthus the control rod.

A problem with using this method is that it is typically not veryaccurate. In particular, it has a low span to offset ratio and a lowsignal span. This is problematic because the measurement instrumentationis typically limited to relatively low signal voltages, and it is thusdesirable to maximise the signal span to offset ratio so that therelative position of the leadscrew (and therefore the control rod) canbe known with high accuracy.

A further problem with the prior art techniques is that the flux densityof the field that is generated around the inductive element is difficultto predict before manufacture. It is common practice, therefore, tomanufacture a multitude of inductive elements, the one with the bestmagnetic field in terms of the spread of the flux ultimately beingselected for use.

Indeed, each element may need to be calibrated in situ, so thatvariations in the local operating environment can be accounted for inthe calibration. This is undesirable.

Some prior art methods of measurement use the transformer principlerather than the simple inductor principle. The transformer principlealso involves a metallic probe tube and a metallic leadscrew, but theprobe tube houses a series of transformer windings alternating betweenelectromagnetically coupled primary and secondary windings along a core.When in operation, a magnetic field is generated between the primary andsecondary windings. As the leadscrew moves over the probe tube themagnetic field between the windings is affected such that the voltagegenerated across the secondary windings changes proportionately to theposition of the leadscrew over the probe tube.

An example of a transformer effect sensor is U.S. Pat. No. 5,563,922,which shows the use of a transformer effect to sense the moving metallicitem through a metallic enclosure. However, in the arrangement shown inU.S. Pat. No. 5,563,922, the output signal typically suffers from a lowspan to offset ratio. As mentioned above is undesirable because itreduces the sensitivity of the sensor and therefore the accuracy towhich the relative position of the leadscrew (and therefore the controlrod) can be known.

In particular, in arrangements similar to that of U.S. Pat. No.5,563,922, the signal span is relatively small. And, typically, a largeresidual magnetic field exists between the primary and secondarywindings when the leadscrew is “covered” (i.e. the leadscrew is arrangedto cover the probe tube). This typically results in a large voltageoffset on the output signal of the sensor, which is undesirable.

In particular, when an output signal is amplified the voltage offset ofthe signal is also amplified, which causes difficulty for subsequentsignalling processing of the output signal; indeed, it can make itdifficult to detect the relevant part of the signal, because it isswamped by the amplified offset level (and any associated noise on theoffset level).

SUMMARY

The present invention seeks to provide a way to remove the undesirableoffset, thus improving the sensor significantly with respect to theknown prior art sensors by providing a sensor with an improved signalspan to offset ratio, thereby providing a sensor with higher resolution.In other words, the present invention seeks to provide a sensor and/ormethod which provides a signal indicating the relative location of ametallic object with a higher degree of accuracy than the prior art.

A first aspect provides a sensor assembly for indicating the relativelocation of a metallic object, the sensor assembly including: a primaryelectromagnetic coil arranged to generate a time varying magnetic field;and a secondary electromagnetic coil arranged to detect the time varyingmagnetic field as affected, directly or indirectly, by the object and tooutput, on the basis of the detected time varying magnetic field, asignal indicative of the relative location of the object; wherein atleast one of the primary and secondary electromagnetic coils is woundabout a core body formed of a material having the same conductivityand/or magnetic permeability as the object. Accordingly, the signal spanto offset ratio of the output of the sensor has a higher resolution thanprior art sensors.

The primary and secondary coils may be arranged coaxially.

A plurality of primary electromagnetic coils may be provided. Aplurality of secondary electromagnetic coils may be provided.

The plurality of primary and secondary coils may be arranged in amutually alternating sequence of primary and secondary coils.

The or each primary coil may be wound about a core body formed of amaterial having the same conductivity and/or magnetic permeability asthe object.

The or each secondary coil may be wound about a core body formed of amaterial having the same conductivity and/or magnetic permeability asthe object.

The primary and secondary coils may each be wound about the same corebody formed of a material having the same conductivity and/or magneticpermeability as the object.

The primary coils may be mutually arranged in electrical series; and/orwherein the secondary coils may be separately mutually arranged inelectrical series.

The primary and/or secondary coils may be formed of an alloy comprising86% copper, 12% Manganese and 2% Nickel, e.g. Manganin® wire.

The or each core body may be formed of a material having the sameconductivity and/or magnetic permeability as the object.

The or each core body may be formed of the same material as the object.

The metallic object may be attached to a (movable) nuclear reactorcontrol rod.

A second aspect provides a method of optimising the output of a sensoras described herein, the method including the steps of:

-   -   supplying the primary coil(s) with an alternating current to        result in the generated time varying magnetic field;    -   locating the object in a first position and recording the signal        output by the secondary electromagnetic coil(s) for a range of        respective frequencies of the supplied alternating current;    -   locating the object in a second position and recording the        signal output by the secondary electromagnetic coil(s) for the        range of respective frequencies of the supplied alternating        current;    -   calculating, for each of the respective frequencies, a value for        the span to offset ratio of the measured signals on the basis of        the respective signals measured for the object in the first and        second positions; and    -   determining the frequency of the supplied alternating current        which provides the maximum span to offset ratio on the basis of        the calculations.

When the object is in the first location, the output from the secondarycoil(s) may be a maximum. When the object is in the second location, theoutput from the secondary coil(s) may be a minimum.

The calculation step may include, for each respective frequency:

-   -   calculating the difference between the amplitudes of the signals        measured for the object in the first and second positions; and    -   dividing the difference by the amplitude of the signal measured        for the object in the second position.

The sensor assembly may include a metallic body, within which theprimary and secondary coils and core body/bodies are located, andoutside of which the metallic object is located.

Thus the sensor assembly is configured to be capable of indicating therelative location of the metallic object even though the coils areseparated from the metallic object by the metallic body (within whichthe coils are located).

A third aspect provides sensor assembly for indicating the location of aleadscrew relative to a probe tube, the leadscrew forming part of anuclear control rod and the probe tube being moveably connected to theleadscrew, the sensor assembly including:

-   -   a primary electromagnetic coil arranged to generate a time        varying magnetic field; and    -   a secondary electromagnetic coil arranged to detect the time        varying magnetic field as affected, directly or indirectly, by        the leadscrew moving relative to the probe tube and to output,        on the basis of the detected time varying magnetic field, a        signal indicative of the location of the leadscrew relative to        the probe tube;    -   wherein the primary electromagnetic coil and/or the secondary        electromagnetic coil comprises copper and nickel.

The primary electromagnetic coil and the secondary electromagnetic coilmay be formed from a copper-manganese-nickel alloy.

The copper-manganese-nickel alloy may comprise by weight equal to orbetween 77 and 89% Copper, 10 and 18% Manganese, 1 and 5% Nickel.

The copper-manganese-nickel alloy may comprise by weight 86% Copper, 12%Manganese and 2% Nickel.

Both the primary electromagnetic coil and the secondary electromagneticcoil may comprise copper and nickel.

The sensor assembly may include a temperature indicator to indicate thetemperature of the sensor assembly.

The sensor assembly may comprise a processor configured to receive thevoltage from the primary electromagnetic coil, the voltage from thesecondary electromagnetic coil and an output from the temperatureindicator and output a calibrated output that compensates for thetemperature of the sensor assembly.

The sensor assembly may comprise a tertiary coil. The tertiary coil maycomprise at least 95% by weight copper, for example at least 98% byweight copper, or at least 99% by weight copper.

The tertiary coil may be positioned to surround the primaryelectromagnetic coil.

The sensor assembly of the third aspect may have one or more of theoptional features of the sensor assembly of the first aspect.

A fourth aspect provides a method of indicating the relative location ofa leadscrew relative to a probe tube, the leadscrew forming part of anuclear control rod and the probe tube being moveably connected to theleadscrew, the sensor being of the type according to the first or thethird aspect, the method including the steps of:

-   -   supplying the primary electromagnetic coil with an alternating        current to result in the generated time varying magnetic field;    -   recording a voltage from the primary coil;    -   recording the signal output by the secondary electromagnetic        coil;    -   recording a temperature indicator indicative of the temperature        of the sensor;    -   modifying the voltage from the secondary electromagnetic coil        based upon the temperature indicator to produce a calibrated        secondary voltage; and    -   calculating a position of the leadscrew based on the calibrated        secondary voltage and the voltage recorded from the primary        coil.

A fifth aspect provides a method of optimising the output of a sensorfor indicating the relative location of a metallic object, the sensorbeing of the type having a primary electromagnetic coil arranged togenerate a time varying magnetic field; and a secondary electromagneticcoil arranged to detect the time varying magnetic field as affected,directly or indirectly, by the object and to output, on the basis of thedetected time varying magnetic field, a signal indicative of therelative location of the object, the method including the steps of:

-   -   supplying the primary coil with an alternating current to result        in the generated time varying magnetic field;    -   locating the object in a first position and recording the signal        output by the secondary electromagnetic coil for a range of        respective frequencies of the supplied alternating current    -   locating the object in a second position and recording the        signal output by the secondary electromagnetic coil for the        range of respective frequencies of the supplied alternating        current;    -   calculating, for each of the respective frequencies, a value for        the span to offset ratio of the measured signals on the basis of        the respective signals measured for the object in the first and        second positions; and    -   determining the frequency of the supplied alternating current        which provides the maximum span to offset ratio on the basis of        the calculations.

The sensor may be a sensor assembly according to the first or the thirdaspects.

When the object is in the first location, the output from the secondarycoil may be a maximum; and/or when the object is in the second location,the output from the secondary coil may be a minimum.

The calculation step may include, for each respective frequency:

-   -   calculating the difference between the amplitudes of the signals        measured for the object in the first and second positions; and    -   dividing the difference by the amplitude of the signal measured        for the object in the second position.

The sensor may be positioned within a metallic tube and the metallicobject may be arranged to move relative to the tube between a positionof minimum overlap and a position of maximum overlap of the tube and theobject.

The first position may be a position where there is minimum overlapbetween the tube and the object.

The second position may be a position where there is maximum overlapbetween the tube and the object.

At least one of the primary and secondary electromagnetic coils may bewound about a core body formed of a material having the sameconductivity and/or magnetic permeability as the object.

The primary and secondary coils may be arranged coaxially.

The sensor may comprise a plurality of primary electromagnetic coils.

The sensor may comprise plurality of secondary electromagnetic coils.

The plurality of primary and secondary coils may be arranged in amutually alternating sequence of primary and secondary coils.

The or each primary coil may be wound about a core body formed of amaterial having the same conductivity and/or magnetic permeability asthe object.

The or each secondary coil may be wound about a core body formed of amaterial having the same conductivity and/or magnetic permeability asthe object.

The primary and secondary coils may be each wound about the same corebody formed of a material having the same conductivity and/or magneticpermeability as the object.

The primary coils may be mutually arranged in electrical series; and/orwherein the secondary coils may be separately mutually arranged inelectrical series.

The or each core body may be formed of a material having the sameconductivity and/or magnetic permeability as the object.

The or each core body may be formed of the same material as the object.

The metallic object may be attached to a nuclear reactor control rod.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described by way of examplewith reference to the accompanying drawings in which:

FIG. 1A shows (half) a cross section of a sensor in situ in a probe tubefor measuring the relative location of a control rod leadscrew, wherethe leadscrew is “uncovered” (i.e. is located distally to the sensor);

FIG. 1B shows (half) a cross section of a sensor in situ in a probe tubefor measuring the relative location of a control rod leadscrew, wherethe leadscrew is “uncovered” (i.e. is located proximally to the sensor);

FIG. 2 shows a cutaway view of a nuclear reactor probe tube andindicates the likely field lines generated;

FIG. 3 shows a plot indicating the effect, at an arbitrary 400 Hz, onthe signal span to offset ratio when the material of the core body ismatched to that of the object to be detected;

FIG. 4 shows a plot indicating the AC supply current frequencydependence of the signal span to offset ratio of the output signal forvarious material of core body;

FIG. 5 shows a plot indicating the effect, at an optimum 7.5 kHz, on thesignal span to offset ratio when the material of the core body ismatched to that of the object to be detected;

FIG. 6 shows a plot of the output signal span at a range of frequencieswith the leadscrew in a first predetermined position;

FIG. 7 shows a plot of the output signal span at a range of frequencieswith the leadscrew in a second predetermined position;

FIG. 8 shows a plot of the signal span to offset ratio for the signalsacross the range of frequencies indicated in FIGS. 6 and 7

FIG. 9 shows a plot of the output signal at a range of positions of theleadscrew at a maximum sensor temperature of 20° C. and 200° C.;

FIG. 10 schematically shows a cross section of a further sensor;

FIG. 11 schematically shows a cross section of the sensor of FIG. 10;

FIG. 12 shows a plot of the output signal from the sensor of FIG. 10 ata range of positions of the leadscrew at a maximum sensor temperature of20° C. and 200° C.; and

FIG. 13 schematically shows a processor for calibrating an output fromthe sensor of FIG. 10.

DETAILED DESCRIPTION

FIG. 1 shows schematic cross sections of a sensor 10. The schematic onlyshows half of the full arrangement; the full arrangement being mirroredabout the dashed line A-A to shown in FIG. 1.

The sensor 10 comprises a plurality of primary coils 12, coaxiallyarranged with a plurality of secondary coils 14. One or more primarycoils 12 may be provided. One or more secondary coils 14 may beprovided.

Where a plurality of primary coils 12 are provided, the respectiveprimary coils may be connected in electrical series. Where a pluralityof secondary coils 12 are provided, the respective secondary coils maybe connected in electrical series.

The primary and secondary coils are arranged in a mutually alternating(physical) series or sequence, such that the sequence of coils along thelong axis of the series alternates between individual primary andsecondary coils. The primary and secondary coils are not in electricalconnection. In other words, between each pair of adjacent primary coils12 a secondary coil 14 may be provided; and/or between each pair ofadjacent secondary coils 14 a primary coil 12 may be provided.

In the embodiment shown, each coil 12, 14 is wound around a single corebody 16. However, the coils may be each be wound around a respectivecore body 16. Or plural sets of two or more of the coils may be woundaround respective core bodies.

The coils 12, 14 may be wound around a supporting body, which is itselfmounted on to the core body 16. However, the coils 12, 14 may be wounddirectly on to the core body 16. In either case the coils 12, 14 may bereferred to as bobbins.

In one particular use, the sensor 10 is mounted inside a probe tube 18which extends or projects into a region containing the primary watersurrounding a nuclear reactor. In this example, for safety reasons theprobe tube must be metallic.

Within the aforementioned region the nuclear reactor control rods (notshown) are movable, to be inserted into or withdrawn from the nuclearreactor itself. Typically, each control rod is attached to a leadscrew20, such that movement of the nuclear rod causes movement of itsrespective leadscrew. It is the accurate detection of the movement, ormore accurately the relocation, of the leadscrew that the presentdisclosure aims to provide.

As the control rod is moved, the leadscrew 20 moves along the probe tube18. At one extreme, the leadscrew may not cover any part of the probetube, as shown in FIG. 1A. This may occur for example when the controlrod is fully inserted into the nuclear reactor core. At another extreme,the leadscrew may fully cover the probe tube, as shown in FIG. 1B, forexample when the control rod is fully withdrawn from the nuclear reactorcore.

Therefore, to assist in the understanding of the present example, FIG.1A shows the leadscrew in the “uncovered” position, whereby theleadscrew 20 is withdrawn from the probe tube 18; whereas FIG. 1B showsthe leadscrew in the “covered” position, whereby the leadscrew 20 isarranged proximate to the sensor, e.g. to cover the probe tube 18. InFIG. 1A the nuclear reactor control rod (not shown) to which theleadscrew 20 is attached may be at a maximum insertion in the nuclearreactor core for example. Whereas, in FIG. 1B the nuclear reactorcontrol rod (not shown) to which the leadscrew 20 is attached may be ata maximum extent of withdrawal from the nuclear reactor core, forexample.

In order to control the reaction within the nuclear reactor core in areliable and safe manner it is important to know the relative locationof the leadscrew 20, and therefore of the control rod, with a highdegree of accuracy.

During operation of a sensor, the primary coils 12 of the sensor 10 aresupplied with an alternating (AC) current so as to result in a timevarying magnetic field being produced by the primary coils 12. The timevarying magnetic field interacts with the local environment, includingthe probe tube 18, the core body 16 and the leadscrew 20.

The time varying magnetic field, as affected by the local environment,induces in the secondary coils 14 a corresponding AC current, and thesecondary coils therefore output a corresponding signal indicative ofthe time varying magnetic field which induced the AC current in thesecondary coils.

Changes in the local environment, such as relocation, or repositioning,of the leadscrew 20 will alter the time varying magnetic field, andtherefore will consequently alter the current induced in the secondarycoils 14. Thus the corresponding output signal will be changed.

This change in the signal output of the secondary coils is detectable,and can be used to establish the relative location of the leadscrew 20,and thus of the control rods.

As discussed above, similar prior art sensor arrangements (e.g. U.S.Pat. No. 5,563,922) suffer from disadvantages that mean the accuracy ofthe determination of the relative location of the leadscrew can beimproved significantly. The present inventor has realised that animportant factor when considering how to improve the accuracy of saiddetermination is the (signal) span to offset ratio.

The signal span is the measurable signal span from the minimum signal tothe maximum signal, and the offset is the minimum achievable signal.

It is often difficult, if not impossible, to achieve a zero offset in ameasured signal. Noise and residual signal inducing effects (e.g.residual magnetic fields in the context of the present discussion) meanthat a non-zero signal offset is almost inevitable in any measurementsystem.

Systems such as that shown in U.S. Pat. No. 5,563,922 often suffer fromrelatively small signal spans and undesirably large signal offsets,meaning that the overall accuracy of the measurement system can suffer.

The present inventor currently considers that the (static) localenvironment around the sensor 10 is responsible for disadvantagesdiscussed above. For example, as shown in FIG. 2, the time varyingmagnetic field 22 generated by the primary coils 12 results in asecondary electromagnetic field 24 in the metallic probe tube 18 (due tothe produced eddy current 26) which can adversely affect the signaloutput by the secondary coils 14 by reducing the signal span to offsetratio for example. Other aspects of the local environment can alsoaffect the signal span and signal offset. For example, the core body 16about which the respective coils are wound.

The present inventor has realised that one way to significantly improvethe (signal) span to offset ratio to achieve excellent accuracy indetermining the relative location of the leadscrew 20, is to ensure thatthe core body 16 is formed of a material having the same permeabilityand/or conductivity as the material from which the leadscrew 20 isformed.

Indeed, in particularly preferred embodiments, the core body 16 isformed of the same material as the leadscrew 20. In such embodiments,ideally, the core body would be formed of the same production batch ofmaterial as the leadscrew 20, although this is not strictly necessaryfor the sensor arrangement to be worked.

FIG. 3 shows a plot demonstrating the advantageous effect on the SoR(signal span to offset ratio) of the output signal of the secondarycoils 12 when the material (or the permeability and/or conductivitycharacteristics) of the core body 16 is matched to the material fromwhich the leadscrew is formed. Line 28 indicates the output signal V_(S)against leadscrew position P for the sensor of the present embodiment.Line 30 is provided for comparison purposes and indicates an outputsignal against leadscrew position for a sensor where the material of thecore 16 is different to the material of the leadscrew 20 (includinghaving a different conductivity and a different magnetic permeability).

To produce FIG. 3, an arbitrary frequency of 400 Hz for the AC currentsupply to the primary coils 12 was chosen.

To calculate the SoR at the arbitrary frequency of 400 Hz, the outputsignal from the secondary coils 14 was measured for the uncoveredleadscrew arrangement (i.e. where the leadscrew is distal to the sensoras in FIG. 1A) and separately for the covered leadscrew (i.e. theleadscrew at least partially ensheathing the sensor 10 and probe tube 16as shown in FIG. 1B). Typically this provides values representative ofthe maximum output signal and the minimum output signal respectively.

The difference between the measured values was then calculated to obtainthe signal span. The result was then divided by the measured signalcorresponding to the covered leadscrew (i.e. at least partiallyensheathing the sensor) which typically corresponds with the offset ofthe measured signal.

The result of the division operation gives the span to offset ratio(SoR) for the output signal at the chosen 400 Hz.

For a typical prior art arrangement without core matching (withoutmatching the material characteristics of the core body 16 to that of theleadscrew 20), the SoR at 400 HZ was determined to be around 0.8 only.

However, for a sensor arrangement according to the present embodiment,which adopts the principle of matching the permeability and/orconductivity characteristics of the core body material to that of theleadscrew material (for example, by matching the material of the corebody 16 to that of the leadscrew 20), the SoR at 400 HZ was determinedto be 2.26.

Thus, the described sensor arrangement can provide a very significantimprovement in the SoR of the output signal from the secondary coils 14.

This is particularly advantageous where the output signal of thesecondary coils may be fed to a measurement system via a dataacquisition card having a maximum input voltage. For example, such dataacquisition cards may have a maximum input voltage of 5V. Therefore,improving the SoR within the available 5V range means that theresolution of the acquired signal is improved, and thus the subsequentprocessing can produce a more accurate result for the determination ofthe relative location of the leadscrew 20.

To demonstrate that matching the conductivity and/or magneticpermeability of the core body material to that of the leadscrew 20 isparticularly advantageous in achieving an optimum SoR for the outputsignal of the secondary coils 14, the present inventor has conductedextensive finite element analysis, a resulting plot of the SoR forvarious metals against the frequency of the AC current supply to theprimary coils 12 is shown in FIG. 4.

In FIG. 4, line 30 is the plot of HAS4104; line 32 is the plot for greycast iron; line 34 is the plot for ingot iron; line 36 is the plot forpowdered iron; line 38 is the plot for supermendur (a cobalt-ironalloy); line 40 is the plot for pure iron; line 42 is the plot forSinimax (a nickel-iron alloy); line 44 is the plot for Mumetal® (anickel-iron alloy); line 46 is the plot for Inconel 625 (anickel-chromium alloy); and line 48 is the plot for stainless steel.

The finite element analysis has shown that the particularcharacteristics of the material of the core body 16 which contribute tothe significant improvement of SoR are the conductivity of the core bodymaterial and the magnetic permeability of the core body material. Inparticular, the finite element analysis has shown that the improvementin the SoR of the output of the sensor 10 to be most significant whenthe magnetic permeability and/or the conductivity values of the corebody material is/are matched closely to the magnetic permeability and/orconductivity values of the material from which the object to be detectedis formed—here, the object to be detected typically being a leadscrew 20formed of a particular metal.

To demonstrate this effect, FIG. 4 shows the primary coils 12 AC currentfrequency dependency of the SoR of the output signal of the secondarycoils 14 for various different materials of core body 16 for a leadscrewformed of a material referred to as HAS 4104, or DGS MS HAS 4104, whichis a stainless having a high magnetic permeability. This material waschosen for the leadscrew material in this study because it is thetypical material from which the leadscrews in nuclear reactors areformed.

As can be seen from FIG. 4, the highest SoR is achieved for a corematerial of HAS4104, i.e. a material matching the material of theleadscrew which is also formed of HAS4104.

So, where leadscrews are typically formed of HAS4104, embodiments foruse in nuclear reactors employing such leadscrews may also have a corebody 16 formed of HAS 4104.

The SoR is also dependent on frequency. Not only will the electricalcircuitry typically demonstrate a resonance peak, but the materials inthe local environment will demonstrate different responses depending onthe frequency of the time varying magnetic field generated by theprimary coils.

For example, a peak at around 7.5 KHz is observed in FIG. 4 when thecore body 16 is formed of HAS4104 material. The SoR at this frequency iscalculated to be around 11.

This result for the SoR is calculated as follows, taking the suitablevoltage values from FIG. 5 (in FIG. 5, line 50 is the line plotted for acore body of HAS4104, and line 52 is for a core body of stainless steel316):

-   -   Core body of HAS4104: (2.35V−0.19V)/0.19V=˜11

As shown in FIG. 5, if an alternative material is used for the core body16, which does not have conductivity and/or permeability characteristicswhich match with the HAS4104 of the leadscrew, the SoR is shown to beonly around 2.8. This result for the SoR is calculated as follows,taking the suitable voltage values from FIG. 5:

-   -   Core body of stainless steel 316: (0.27V−0.07)/0.07=˜2.8

Therefore, the described sensor arrangement surprisingly offers animprovement in the SoR of almost four times. Interestingly, this isachieved with an alternative material which is not a wildly differentmaterial to HAS4104, but which is another stainless steel: stainlesssteel 316.

The present inventor has therefore demonstrated that a careful selectionof the material for the core body 16 can have a surprisingly largeadvantageous effect on the SoR of the output signal of the secondarycoils 14.

As can be seen from FIG. 4, the optimum SoR is provided at a particularfrequency, and so the present disclosure also proposes a method fordetermining the frequency at which the optimum SoR exists for aparticular system.

The object to be detected, for example the leadscrew 20, is arrangeddistally from the sensor 10; for example at its furthest distance fromthe sensor 10. In the case of the leadscrew, the control rod may befully inserted into the nuclear reactor, for example.

With the leadscrew 20 in this position, the primary coils are providedwith AC current at a range of (two or more) discrete frequencies f, andthe output signal V_(S) from the secondary coils measured and recordedfor each respective frequency.

The result of such an exercise is shown in FIG. 6 for example.

The object to be detected, for example the leadscrew 20, is alsoarranged at proximally to the sensor 10; for example at its nearestposition to the sensor 10. In the case of the leadscrew 20, the controlrod may be at its maximum withdrawal from the nuclear reactor forexample.

With the leadscrew in this position, the primary coils 12 are providedwith AC current at the same range of the same (two or more) discretefrequencies f, and the output signal V_(S) from the secondary coils 14measured and recorded for each respective frequency.

The result of this exercise is shown in FIG. 7 for example, where theeffect of the object (the leadscrew) on the signal output by thesecondary coils 14 can clearly be seen by comparison of FIG. 7 with FIG.6.

Then the SoR at each frequency is determined in accordance with thecalculation discussed above in relation to FIG. 5, to determine thefrequency f at which the SoR is a maximum. In other words, for eachfrequency, the minimum measured output signal is subtracted from themaximum measured signal to generate a difference value, and thedifference value is divided by the minimum value to generate the SoRvalue.

For the range of frequencies f measured, FIG. 8 shows a plot of the SoR.As can be seen, for the particular arrangement used in thedemonstration, the SoR reaches a maximum value of around SoR=11.4 ataround 6.75 kHz.

Therefore, for the particular sensor and the local environment in whichthe sensor was located in this demonstration, the AC current shouldideally be supplied to the primary coils 12 at around 6.75 KHz in orderto maximize the SoR of the output signal of the secondary coils.

Accordingly, the present embodiment provides a position sensor whichprovides an output signal indicative of the relative position of anobject to be detected with a higher resolution than equivalent sensorarrangements in the prior art.

This is achieved by winding the primary coil(s) and secondary coil(s)around one or more core bodies formed of a material having similarcharacteristics to the material of the object to be detected. Inparticular, it is preferred that the material of the one or more corebodies has a conductivity and/or magnetic permeability which matches thematerial of the object to be detected. In most preferred embodiments,the material of the one or more bodies is the same as the material ofthe object to be detected.

In this way, a sensor arrangement according to the present embodimentprovides a higher SoR and span output signal when detecting metallicobjects through another metallic body. This provides major advantages inhigh accuracy and resolution measurement systems. The ability to providethe downstream instrumentation detection electronics with goodresolution sensor signals enables errors to be reduced significantly,thereby allowing the overall system to be more accurate and to offerbetter resolution.

In particular, a sensor according to the present embodiment, especiallywhen used in conjunction with the SoR optimisation technique disclosedherein, offers a greatly improved means to measure linear displacementof a metallic device through another metallic device.

In the sense that a sensor 10 according to the present embodimentgenerates a signal for interaction with the local environment andmeasures the effect on the signal in order to output a signal indicativeof a change in the local environment, the sensor 10 may be considered tobe a transducer, and may be referred to as such.

As mentioned above, a sensor according to the present embodiment isparticularly suited to use in a nuclear reactor, where the temperatureof the local environment may fluctuate to a large extent. A largefluctuation in temperature will likely change the resistive propertiesof the primary and/or secondary coils, and therefore will likely changethe SoR of the output signal of the secondary coils.

Referring to FIG. 9, the output V_(S) from the secondary coil 14 atvarying positions of the leadscrew 20 is illustrated for a sensor 10where the primary coil 12 and the secondary coil 14 are made fromcopper. The line 60 indicates the variation of the output V_(S) from thesecondary coil for varying positions P of the leadscrew at 200° C. andline 62 indicates the variation of the output from the secondary coilfor varying positions of the leadscrew at 20° C. The temperatures givenare measured at a position on the sensor having a maximum temperature,in this case this is in a region at the bottom of the probe tube 18. Itcan be seen from FIG. 9, that a change in maximum temperature from 200°C. to 20° C. significantly affects the output from the secondary coil.This means that the output from the secondary coil is undesirablydependent upon the temperature of the system. Furthermore, at lowertemperatures the change in output for a given position change of theleadscrew decreases, which in turn impacts the sensitivity of thesensor.

Referring to FIG. 10 a sensing arrangement that attempts to address thistemperature dependence problem is illustrated. The arrangement of FIG.10 is similar to the arrangement previously described, and similarfeatures are given a similar reference numeral but with a pre-fix “1” todistinguish between embodiments. Only the differences between theembodiments will be described in detail.

As illustrated in FIG. 10, similar to the previously describedembodiment, the arrangement includes a sensor 110 positioned in a probetube 118, and the probe tube 118 is moveable relative to a leadscrew120.

Referring now to FIG. 11, the sensor 110 is shown in more detail.Similar to the previously described sensor, the sensor 110 includes aseries of primary coils 112 and secondary coils 114. In the presentlydescribed embodiment, the primary coils and the secondary coils are madefrom a copper-manganese-nickel alloy. In particular, the primary andsecondary coils are made from Manganin®. Manganin® is aCopper-manganese-nickel alloy, and is generally provided in the ratio of86:12:2 by weight.

FIG. 12 illustrates the output V_(S) from the secondary coil 114 atvarying positions P of the leadscrew. Line 64 illustrates the outputfrom the secondary coil at 200° C. and line 66 illustrates the outputfrom the secondary coil at 20° C. As can be seen from FIG. 12, the useof manganin wire significantly reduces the temperature dependence of theoutput from the secondary coil both in terms of magnitude for a givenposition of the leadscrew as well as in terms of the change in magnitudefor a step change in position of the leadscrew.

However, it can be seen from FIG. 12 that there is still some variationin the output V_(S) from the secondary coil 114. It is believed thatthis variation is due to probe tube and leadscrew thermal effects,primarily probe tube thermal effects.

Referring again to FIG. 11, the sensor 110 is further optimised toinclude a tertiary coil 115. The tertiary coil is arranged substantiallycoaxially with the primary coil 112 and is positioned radially outsideof the primary coil. However, in alternative embodiments the tertiarycoil could surround the secondary coil or surround both the primary andsecondary coils, or be positioned at any other suitable position on thecore 116. The tertiary coil is made from copper or an alloy thereof.

Referring now to FIG. 13, the sensor is connected to a processor 168.The voltage V_(p) from the primary coil, the Voltage V_(S) from thesecondary coil and the Voltage V_(T) from the tertiary coil aretransmitted to the processor. The processor receives the voltage fromthe primary coil, secondary coil and tertiary coil and performs acompensation procedure. The algorithm for the compensation procedure canbe established using techniques known in the art and will vary dependingon the specific environment in which the sensor is used. Once theprocessor has performed the compensation procedure, the processoroutputs a calibrated secondary coil output V_(SC). The compensationprocedure can remove the variation in output from the secondary coilillustrated in FIG. 12, so that the calibrated secondary coil outputV_(SC) is independent of the temperature of the sensor.

In alternative embodiments, the primary and secondary coils may be madefrom an alloy such as constantan (a copper-nickel alloy). However, theinventor has found Manganin® to provide an optimum SoR.

In the present embodiment, the tertiary coil is provided with an ACcurrent, but in alternative embodiments the tertiary coil may beprovided with a DC current. In further alternative embodiments, thetertiary coil may be replaced with another type of temperatureindicator.

It will be appreciated by one skilled in the art that, where technicalfeatures have been described in association with one or moreembodiments, this does not preclude the combination or replacement withfeatures from other embodiments where this is appropriate. Furthermore,equivalent modifications and variations will be apparent to thoseskilled in the art from this disclosure. Accordingly, the exemplaryembodiments of the invention set forth above are considered to beillustrative and not limiting.

The invention claimed is:
 1. A method of optimising the output of asensor for indicating the relative location of a metallic object, thesensor being of the type having a primary electromagnetic coil arrangedto generate a time varying magnetic field; and a secondaryelectromagnetic coil arranged to detect the time varying magnetic fieldas affected, directly or indirectly, by the object and to output, on thebasis of the detected time varying magnetic field, a signal indicativeof the relative location of the object, the method including the stepsof: supplying the primary coil with an alternating current to result inthe generated time varying magnetic field; locating the object in afirst position and recording the signal output by the secondaryelectromagnetic coil for a range of respective frequencies of thesupplied alternating current; locating the object in a second positionand recording the signal output by the secondary electromagnetic coilfor the range of respective frequencies of the supplied alternatingcurrent; calculating, for each of the respective frequencies, a valuefor the span to offset ratio of the measured signals on the basis of therespective signals measured for the object in the first and secondpositions, the calculating step including, for each respective frequencycalculating the difference between the amplitudes of the signalsmeasured for the object in the first and second positions, and dividingthe difference by the amplitude of the signal measured for the object inthe second position; and determining the frequency of the suppliedalternating current which provides the maximum span to offset ratio onthe basis of the calculations.
 2. A method according to claim 1, whereinwhen the object is in the first position, the output from the secondarycoil is a maximum; and/or when the object is in the second position, theoutput from the secondary coil is a minimum.
 3. A method according toclaim 1, wherein at least one of the primary and secondaryelectromagnetic coils of the sensor is wound about a core body formed ofa material having the same conductivity and/or magnetic permeability asthe object.
 4. A method according to claim 1 wherein the primary andsecondary coils of the sensor are arranged coaxially.
 5. A methodaccording to claim 1, wherein the primary coil of the sensor is woundabout a core body formed of a material having the same conductivityand/or magnetic permeability as the object.
 6. A method according toclaim 1, wherein the secondary coil of the sensor is wound about a corebody formed of a material having the same conductivity and/or magneticpermeability as the object.
 7. A method according to claim 1, whereinthe primary and secondary coils of the sensor are each wound about thesame core body formed of a material having the same conductivity and/ormagnetic permeability as the object.
 8. A method according to claim 1,wherein the primary coils of the sensor are mutually arranged inelectrical series; and/or wherein the secondary coils of the sensor areseparately mutually arranged in electrical series.
 9. A method accordingto claim 1 wherein the primary and/or secondary coils of the sensor areformed of an alloy comprising 86% copper, 12% Manganese and 2% Nickel.10. A method according to claim 1 wherein a core body of the sensor isformed of a material having the same conductivity and/or magneticpermeability as the object.
 11. A method according to claim 1 wherein acore body of the sensor is formed of the same material as the object.12. A method according to claim 1, wherein the metallic object isattached to a nuclear reactor control rod.
 13. A method according toclaim 1, wherein the sensor is positioned within a metallic tube and themetallic object is arranged to move relative to the tube between aposition of minimum overlap and a position of maximum overlap of thetube and the object.
 14. A method according to claim 13, wherein thefirst position is a position where there is minimum overlap between thetube and the object.
 15. A method according to claim 13, wherein thesecond position is a position where there is maximum overlap between thetube and the object.
 16. A method according to claim 1, wherein thesensor includes a plurality of primary electromagnetic coils.
 17. Amethod assembly according to claim 16, wherein the sensor includes aplurality of secondary electromagnetic coils.
 18. A method assemblyaccording to claim 17, wherein the plurality of primary and secondarycoils are arranged in a mutually alternating sequence of primary andsecondary coils.